Artificial leather and method for manufacturing the same

Abstract

In order to provide artificial leather having both strength (in particular, tensile strength and tear strength), surface appearance, and a dense feeling in artificial leather including a fiber-entangled body containing a nonwoven fabric made of ultrafine fibers containing a large amount of inorganic particles (in particular, metal compounds) as a constituent element, and an elastic polymer, the artificial leather of the present invention is artificial leather including a fiber-entangled body containing a nonwoven fabric made of ultrafine fibers having an average single fiber diameter of 1.0 μm or more and 10.0 μm or less as a constituent element and an elastic polymer, and satisfies the following requirements: (1) the ultrafine fibers include a polyester-based resin containing a manganese-based compound; (2) an average particle diameter of the manganese-based compound is 0.01 μm or more and 0.20 μm or less; and (3) the ultrafine fibers contain a manganese element in an amount of 0.1 ppm or more and 50.0 ppm or less in 100 mass % of the ultrafine fiber.

1 . Artificial leather comprising:
 a fiber-entangled body containing a nonwoven fabric made of ultrafine fibers having an average single fiber diameter of 1.0 μm or more and 10.0 μm or less as a constituent element and   an elastic polymer,   wherein the artificial leather satisfies the following requirements:   (1) the ultrafine fibers include a polyester-based resin containing a manganese-based compound;   (2) an average particle diameter of the manganese-based compound is 0.01 μm or more and 0.20 μm or less; and   (3) the ultrafine fibers contain a manganese element in an amount of 0.1 ppm or more and 50.0 ppm or less in 100 mass % of the ultrafine fiber.   
     
     
         2 . The artificial leather according to  claim 1 , wherein the ultrafine fibers further contain a phosphorus-based compound. 
     
     
         3 . The artificial leather according to  claim 2 , wherein a manganese element molar equivalent A contained in the ultrafine fibers and a phosphorus element molar equivalent B contained in the ultrafine fibers satisfy a relationship of a molar ratio of the following formula (I):
   20 ≤B/A≤ 200  (I).
   
     
     
         4 . The artificial leather according to  claim 1 , wherein the ultrafine fibers further contain carbon black. 
     
     
         5 . The artificial leather according to  claim 1 , wherein the fiber-entangled body includes only the nonwoven fabric. 
     
     
         6 . The artificial leather according to  claim 1 , wherein the fiber-entangled body further includes a woven fabric, and the nonwoven fabric and the woven fabric are entangled and integrated. 
     
     
         7 . A method for manufacturing artificial leather according to  claim 1 , the method comprising:
 a sea-island type composite fiber forming step of performing sea-island type composite spinning using a polyester-based resin containing a manganese-based compound having an average particle diameter of 0.01 μm or more and 0.20 μm or less as an island component and a thermoplastic resin having different solvent solubility from the island component as a sea component;   a fiber-entangled body forming step of forming a fiber-entangled body including the sea-island type composite fiber;   an ultrafine fiber forming step of dissolving and removing the sea component from the sea-island type composite fiber to form ultrafine fibers having an average single fiber diameter of 1.0 μm or more and 10.0 μm or less; and   an elastic polymer applying step of applying an elastic polymer to the fiber-entangled body.